Picket assembly

ABSTRACT

The present invention provides embodiments of wrought iron picket assemblies having fasteners for mounting wooden hand rails for use in constructing railings, said fasteners also serving a fixing function during surface treatment of a picket.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to Provisional Application Ser. No. 60/705,325, filed Aug. 4, 2005, titled “A Picket Assembly For Mounting a Handrail,” which is hereby expressly incorporated by reference in its entirety.

TECHNICAL FIELD

The present invention relates to picket and hand rail fastener assemblies for railings.

BACKGROUND ART

Railings are typically used for a variety of useful reasons such as helping to prevent a ball, dog, or person from leaving or entering an area. For example, a railing may be constructed across an edge of deck to help prevent a person on the deck from unintentionally falling over the deck's edge. Or, a railing may be constructed to confine a dog within a backyard of a home. Railings consisting of wrought iron pickets and wooden hand rails are particularly popular because of the marriage of low-maintenance utility of the wrought iron pickets, with the comfort and warm attractiveness of the wooden hand rails. Coupling wrought iron pickets with hand rails is generally accomplished by press fitting a cylindrical section lathed into an end of a picket, into cylindrical hold drilled into the underside of a hand rail. Sometimes epoxy or a similar adhesive may be deposited into the cylindrical hole prior to assembly in order to further secure the handrail. The process of lathing a cylindrical section of a wrought iron picket can be expensive and sometimes difficult. Additionally, it is desirable to have a means for securing the picket during surface coating treatment such as, for example, painting, powder coating, anodization, or plating prior to assembly in a railing.

In view of the above discussion, it is very desirable to have a means for fastening a wooden hand rail to a wrought iron picket without the need to lathe a cylindrical section into an end of the picket. It is additionally desirable that the fastening means also serve as a fixing means for holding the picket during surface coating treatment, and/or storage and transportation.

SUMMARY OF THE INVENTION

The present invention provides embodiments of wrought iron picket assemblies having fasteners for mounting wooden hand rails, said fasteners also serving a fixing function during surface treatment of a picket.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an exploded view of an embodiment of the invention.

FIG. 2 illustrates an assembled view of an embodiment of the invention.

FIGS. 3 a through 3 h show exemplary top views of head cross-sections for various embodiments of the invention.

FIG. 4 illustrates a breakaway appendage for an embodiment of the invention.

FIG. 5 illustrates an assembled view of an embodiment of the invention using a breakaway appendage.

FIG. 6 illustrates a bolt and sleeve assembly for an embodiment of the invention.

FIG. 7 a illustrates a cross-sectional view of a bolt and washer stack assembly for another embodiment of the invention.

FIG. 7 b illustrates a top view of the washer stack according to the embodiment of FIG. 7 a.

FIG. 8 illustrates an assembled view of an embodiment of the invention using a bolt and sleeve assembly.

FIG. 9 illustrates an assembled view of an embodiment of the invention with a handrail in place.

FIGS. 10 a and 10 b illustrate embodiments of the invention as shown in FIG. 6, with washers having breakaway appendages.

FIG. 11 illustrates an embodiment of the invention with a press fit handrail fastener.

FIG. 12 illustrates a method of surface treatment with picket and fastener assemblies mounted according to another embodiment of the invention.

FIG. 13 a illustrates a side view of another embodiment of the invention.

FIG. 13 b illustrates a cross-sectional view of the embodiment of FIG. 13 a.

FIG. 13 c illustrates a top view of the embodiment of FIG. 13 a.

FIG. 13 d illustrates a bottom view of the embodiment of FIG. 13 a.

FIG. 14 d illustrates an exploded view of a rail and picket assembly using the embodiment of FIG. 13 a.

Commonly numbered drawing elements in the various figures refer to common elements of the embodiments of the invention. The drawings of the embodiments shown in the figures are not necessarily to scale. The drawings of the embodiments shown in the figures are for purposes of illustration only, and should not be construed to limit the scope of the invention.

MODES OF CARRYING OUT THE INVENTION

FIG. 1 illustrates an exploded cross-sectional view of an embodiment of the invention. A wrought iron picket 001 has a tapped cavity 010, coaxially oriented with a longitudinal axis, formed in one end as shown. A coupling member 002 is shown having a head 008 attached to one end of threaded shaft 009. The threads on shaft 009 are complementary to the threads of cavity 010. Alternatively, cavity 010 may be unthreaded, and the threads on shaft 009 can be self-tapping. Slot 005 is an optional slot for interfacing with a torquing tool (not shown) for screwing coupling member 002 into cavity 010. Although a slot is illustrated, other torquing tool interfaces such as Philips, hex, and so forth can be used as readily apparent to one of ordinary skill in the art. Head 008 is also shown with a through hole 007 formed in it, transverse to the axis of coupling member 002. Transverse hole 007 is optional, and may be used to fixture the picket assembly (for example, by hanging on a hook) during subsequent processing, such as surface treatment. The circumferential ridge 006 is an optional feature that may be formed in head 008 to assist in fastening a hand rail. Although one circumferential ridge 006 is illustrated, multiple circumferential ridges may be used (as shown, for example, in FIG. 2). Alternatively, other ridge configurations can be used, such as ridges parallel to the cylindrical axis of the head, or other texture patterns can be used such as knurling, embossments, and the like to help lock the head into the handrail.

Referring again to FIG. 1, hand rail 003 is shown with a cylindrical cavity 004 formed in it to accommodate head 008. The fit of cylindrical cavity 004 and head 008 can be tight enough that the natural elasticity of the wooden hand rail makes good press-fit contact, but not so tight as to prevent assembly, or cause damage to the wooden hand rail and/or the wrought iron picket. Epoxy or other suitable adhesives may be deposited in cylindrical cavity 004 prior to assembly, to further secure the wooden hand rail to the wrought iron picket.

The picket and fastener assembly can be made by screwing coupling member 002 into cavity 010 of picket 001. Once assembled, transverse hole 007 of coupling member 002 can serve as a holding fixture feature for the assembly, during subsequent processing such as surface coating treatment, and/or packing, storing, and shipping. When it comes time to assemble the picket assembly with the hand rail, hand rail cavity 004 is press fit onto the head of coupling member 002 as shown in FIG. 2.

Although the head 008 of coupling member 002 has been illustrated as cylindrical, that is having a circular-cross section as shown in FIG. 3 h, other forms with horizontal cross-sections as shown, for example the polygonal prisms of FIGS. 3 a through 3 h are readily contemplated by one of ordinary skill in the art for use to advantage for some types of wood hand rails. Also, the horizontal cross-sections can be tapered along the longitudinal axis of the coupling member. For example, a head can be a tapered cylinder (i.e. a truncated cone) rather than a cylinder in some embodiments of the invention. A polygonal prism can likewise be tapered. Heads of all types of cross-section can have one or more circumferential ridges or bosses to enhance the press fit of the coupling member head with the hand rail. The polygonal prism configurations can also be torqued with a vise-grip, pliers, or a compatible wrench.

Referring again to FIG. 1, coupling member 002 may be fabricated of any appropriate metal, polymer, or, composite material. Metals such as steel, brass, or copper can be formed and machined according techniques that are well known in the hardware arts. Polymer materials such as Nylon® or ABS can be molded and/or machined using similarly well-known techniques, as can composite materials such as carbon or fiber loaded epoxy. The choice of material for coupling member 002 is influenced in part by whether or not an adhesive is used to attach the handrail. For example, if an epoxy adhesive is used, a carbon or fiber loaded epoxy material might form the strongest bond. The need for coupling member 002 to be electrically conductive during some types of surface treatments for the picket assembly would indicate the use of a metal.

In some embodiments, a washer having a breakaway appendage such as illustrated in FIG. 4 can be used as an alternative to through hole 007. Washer 041 defines a hole 046, and is coupled to an appendage (comprising optional extender section 042, coupled to a secondary washer 043, defining a hole 044 for attachment to a holding fixture) by coupling section 045. Coupling section 045 is shown as being “necked in” to facilitate breakage and the removal of the appendage when desired. Alternatively, coupling section 045 could be scored and/or otherwise weakened to facilitate breakage and removal. As discussed above in connection with materials for coupling member 002, the washer having a breakaway appendage 040 may be fabricated of any appropriate metal, polymer, or, composite material.

FIG. 5 illustrates a picket/coupling member assembly with a washer having a breakaway appendage 040. In this embodiment, the head of coupling member 002 requires no transverse hole 007. Instead, washer section 041 of the washer having a breakaway appendage is positioned around the shaft of coupling member 002, between the head of coupling member 002 and the end of picket 001 as pictured. The head of coupling member 002 secures the washer having a breakaway appendage 040 in place. The breakaway appendage 043 is pictured slightly bent upward, although it could otherwise be flat, or even bent downward. Hole 044 of washer section 043 can be used to hang, or otherwise hold in place, the picket/coupling member assembly during subsequent processing such as surface coating treatment, and/or packing, storing, and shipping. When it comes time to assemble the picket assembly with the hand rail, coupling 045 of the washer with a breakaway appendage 040 can be broken, and the only part that remains with the picket/coupling member assembly would then be washer section 041, which would remain in place.

In another embodiment of the invention, a coupling member for a picket and a handrail can be made using a bolt 060, and a cylindrical sleeve 061, as shown in cross-section in FIG. 6.

FIG. 7 a illustrates an alternate embodiment of the embodiment of FIG. 6, in which cylindrical sleeve 061 of FIG. 6 is replaced with a stack of washers 062, shown in cross section. FIG. 7 b is a top view of the stack of washers 062. Although this embodiment has more parts than the embodiment of FIG. 6, the height of the stack of washers can be easily adjusted by including more or fewer washers, and the outside perimeter of the washer stack can provide a textured, gripping surface for coupling with the walls of a hole drilled in a handrail, for example, by alternately stacking washers of different outer diameters.

FIG. 8 illustrates the cylindrical sleeve 061 of the embodiment of FIG. 6, coaxially disposed about bolt 060 that is screwed into an end of picket 001. FIG. 9 illustrates a hand rail press fit onto the assembly shown in FIG. 8.

It is difficult to implement the bolt/cylindrical sleeve or washer stack assemblies shown in FIGS. 6, 7, and 8 with a transverse hole 007 as shown in FIG. 1 because of mechanical interference from the bolt. Consequently, the washer with a breakaway appendage of FIG. 4 can be used to advantage to provide a temporary fixing means for the picket/coupling member assembly. FIGS. 10 a and 10 b illustrate embodiments of picket/coupling member assemblies using bolt/cylindrical sleeve assemblies for coupling members. In the embodiment of FIG. 10 a, the washer with a breakaway appendage 040 is positioned between the cylindrical sleeve 061 and the end of picket 001. In the embodiment of FIG. 10 b, the washer with a breakaway appendage 040 is positioned between the cylindrical sleeve 061 and the head of bolt 060. As described above, when it comes time to assemble the picket assembly with the hand rail, coupling 045 of the washer with a breakaway appendage 040 can be broken, and the only part remaining with the picket/coupling member assembly would then be washer section 041, which would remain in place.

FIG. 11 illustrates an embodiment of the invention similar to the embodiment described in connection with FIG. 1, except that threaded shaft 101 is replaced with tapered section 103, and complementary threaded cavity 010 is replaced with complementary tapered cavity 101. The tapered section 103 of coupling member 102 is press fit into cavity 101 of picket 001 to make the picket/coupling member assembly. Although not illustrated, the head section 104 can be formed in exterior forms as discussed above in connection with FIG. 3. Also, one or more circumferential or radial ridges, bosses, or knurling may be formed in head section 104 to enhance the press fit with the wooden handrail. One or more circumferential ridges or bosses may be formed in the tapered section 103 of coupling member 102 to enhance the press fit with the picket. Head section 104 may also comprise a transverse through hole, as discussed in connection with FIG. 1. As discussed above, coupling member 102 may comprise metal, polymer, or composite material.

FIG. 12 illustrates a use of a fixing feature of an embodiment of the invention. A picket/connecting member assembly 111 is hung from a supporting rod 113 by as hook or wire 112 through a transverse hole or a breakaway appendage of picket/connecting member assembly 111. Sprayer 114 is shown spraying the hanging picket/connecting member assembly 111. Alternatively the hanging picket/connecting member assembly 111 can be dipped into a surface treatment bath.

FIG. 13 illustrates an alternate embodiment of the invention, wherein a cap 137 with a coupled peg 136 is configured to fit over the end of a picket, and coupled peg 136 is configured to fit into a hole in a handrail. FIG. 13 a shows a side view. FIG. 13 b shows a cross-sectional view. FIG. 13 c shows a top view. And, FIG. 13 d shows a bottom view.

FIG. 14 illustrates an exploded view of the embodiment of FIG. 13. The cap and coupled peg 141 can have picket 144 inserted into the cavity of the cap. Pickett 144 may be fixed in the cavity of the cap, for example, (i) by using adhesives such as epoxy, (ii) by welding or soldering, (iii) by press or interference fit, or (iv) using a set screw or rivet. Other modes of fixation are readily apparent to one of ordinary skill in the art. The peg of the cap and coupled peg 141 can be fixed in hole 143 of handrail 142, as described above in conjunction with other embodiments of the invention. Picket 144 and cap with coupled peg 141 may be assembled before or after the peg of the cap with coupled peg 144 is assembled with handrail 144, depending on an installer's preference.

All of the options regarding-cross sectional configurations, tapering, through holes, and surface texturing and/or ridges and embossments described above in connection with the coupling member head embodiment also apply to the cap with coupled peg 141.

Referring again to FIG. 14, the cap coupled to the peg 141 may be fabricated of any appropriate metal, polymer, or, composite material. Metals such as steel, brass, or copper can be formed and machined according techniques that are well known in the hardware arts. Polymer materials such as Nylon® or ABS can be molded and/or machined using similarly well-known techniques, as can composite materials such as carbon or fiber loaded epoxy.

Referring again to FIGS. 13 and 14, the cap 137 is shown configured for a picket with a square cross-section, alternatively, the cap can be configured for a picket with any arbitrary cross section, such as for example: circular, elliptical, or polygonal.

Variations and extensions of the embodiments described are apparent to one of ordinary skill in the art. Other applications, features, and advantages of this invention will be apparent to one of ordinary skill in the art who studies this invention specification. Therefore, the scope of this invention is to be limited only by the following claims. 

1. A picket assembly for mounting a handrail, comprising: a picket having first and second ends, and a longitudinal axis therebetween; a coupling member having a shaft with first and second ends, and having a head coupled to the first end; wherein the first end of the picket has a cavity along the longitudinal axis to conform to the shaft of the coupling member; and wherein the shaft of the coupling member is positioned inside the cavity of the first end of the picket.
 2. The picket assembly of claim 1, wherein the head of the coupling member is disposed coaxially with the shaft, as one of (i) a cylinder, (ii) a conical section, (iii) a polygonal prism, or (iv) a tapered polygonal prism.
 3. The picket assembly of claim 1, wherein the head of the coupling member defines a hole therethrough, transverse to the longitudinal axis of the picket.
 4. The picket assembly of claim 1, wherein the head further comprises at least one feature formed in the surface thereof to grip a hole in a handrail.
 5. The picket assembly of claim 4, wherein a feature formed in the surface of the head comprises one of (i) a circumferential ridge, (ii) an axial ridge, (iii) an embossment, or (iv) a knurling.
 6. The picket assembly of claim 1, wherein the shaft is threaded and the cavity is tapped with complementary threads, and wherein the shafte is positioned within the cavity by screwing.
 7. The picket assembly of claim 1, wherein the shaft is threaded with self-tapping threads, and wherein the shaft is positioned within the cavity by screwing.
 8. The picket assembly of claim 1, wherein the head of the coupling member has a structure formed in a surface thereof distal to the threaded shaft of the coupling member for torquing the coupling member.
 9. The picket assembly of claim 1, further comprising a washer having a breakaway appendage disposed on the shaft of the coupling member between the coupling member and the picket.
 10. The picket assembly of claim 1, wherein the head further comprises at least one feature formed in the surface thereof to grip a hole in a pickett.
 11. The picket assembly of claim 10, wherein a feature formed in the surface of the head comprises one of (i) a circumferential ridge, (ii) an axial ridge, (iii) an embossment, or (iv) a knurling.
 12. A picket assembly for mounting a handrail, comprising: a picket having first and second ends and a longitudinal axis therebetween; a sleeve having with first and second ends, a longitudinal axis therebetween, the exterior of the sleeve formed as one of (i) a cylinder, (ii) a conical section, (iii) a polygonal prism, or (iv) a tapered polygonal prism, and forming a hole extending through the longitudinal axis thereof; a bolt comprising a threaded shaft having first and second ends, and having a bolt head at a first end; wherein the first end of the picket has a tapped hole along the longitudinal axis thereof to conform to the threaded shaft of the bolt; wherein the sleeve is disposed coaxially with the threaded shaft of the bolt, between the first and second ends of the bolt; and wherein the second end of threaded shaft of the bolt, is screwed into the tapped hold of the first end of the picket.
 13. The assembly of claim 12, further comprising a washer with a breakaway appendage disposed between the bolt head and the sleeve.
 14. The assembly of claim 12, further comprising a washer with a breakaway appendage disposed between the sleeve and the picket.
 15. A method for assembling a picket having first and second ends with a longitudinal axis therebetween and defining a hole along the longitudinal axis at the first end that is complementary to a shaft, and a connecting member having a head coupled to the shaft, comprising inserting the shaft into the complementary cavity.
 16. The method of claim 15, wherein a washer with a breakaway appendage is inserted on the shaft, prior to the inserting of the shaft into the cavity.
 17. The method of claim 15, in which the bolt is threaded, the cavity is tapped with complementary threads, and the shaft is inserted into the cavity by screwing.
 18. The method of claim 15, wherein the bolt is threaded with self-tapping threads, and wherein the shaft is positioned within the cavity by screwing.
 19. The method of claim 15, in which the shaft has at least one circumferentially positioned ridge or boss.
 20. The method of claim 15, wherein the head further comprises at least one feature formed in the surface thereof to grip a hole in a handrail.
 21. The method of claim 20, wherein the feature formed in the surface of the head comprises one of (i) a circumferential ridge, (ii) an axial ridge, (iii) an embossment, or (iv) a knurling.
 22. A picket assembly for mounting a handrail, comprising: a picket having first and second ends and a longitudinal axis therebetween; a coaxially stacked plurality of washers; a bolt comprising a threaded shaft having first and second ends, and having a bolt head at a first end; wherein the first end of the picket has a tapped hole along the longitudinal axis thereof to conform to the threaded shaft of the bolt; wherein the coaxially stacked plurality of washers is disposed coaxially with the threaded shaft of the bolt, between the first and second ends of the bolt; and wherein the second end of threaded shaft of the bolt, is screwed into the tapped hold of the first end of the picket.
 23. A cap with a coupled peg for assembling a picket and handrail having a picket mounting hole formed therein comprising: the cap defining a cavity for insertion over the end of the picket; and the peg coupled to the cap, distally to the picket insertion point, configured for insertion into the hole in the handrail.
 24. A picket for mounting into a handrail, comprising: a longitudinal axis between a first and second end, wherein the first end comprises a tapped cavity coaxially oriented to the longitudinal axis and conformed to hold a coupling member. 